Input Shaft, Disassembling and Assembling

Input shaft, disassembling and assembling

Special tools and equipment





^ VW401 Thrust plate
^ VW402 Thrust plate
^ VW407 Press tool
^ VW408 A Press tool
^ VW412 Press tool VW416BTube

Special tools and equipment





^ VW433 Press piece
^ VW454 Press piece
^ VW801 Holding plate
^ VAG1582 tapered roller bearing puller
^ VAG1582/7 Grip
^ 1 - Kukko 21/7 Internal puller
^ 3- Kukko 17/2 Separating device
^ 4 - Kukko 22/2 Counter support

Special tools and equipment





^ 40-105 Thrust plate
^ 41-501 Drift sleeve
^ 2040 Tube
^ 2050 Thrust piece
^ 3074 Press disc
^ 3161 Extension





Note:
^ When installing new gears, consult technical data.

^ If the position of the tapered roller bearings is affected when exchanging parts, the input shaft must be re-adjusted.
1 - Transmission housing
2 - Shim
3 - Tapered roller bearing outer race
4 - Circlip
^ Redetermine if tapered roller bearing -item - 5 - or input shaft -item 8 - are replaced, Refer to Fig. 11
5 - Tapered roller bearing inner race
^ Pulling off, Refer to Fig. 3
^ Pressing on, Refer to Fig. 10
6 - 5th gear
^ Pressing off, Refer to Fig. 4
^ Pressing on, Refer to Fig. 9
7 - 3rd, 4th and 6th gear
^ Pressing off, Refer to Fig. 5
^ Pressing on, Refer to Fig. 7
8 - Input shaft
9 - Tapered roller bearing inner race
^ Pressing off, Refer to Fig 6
^ Pressing on, Refer to Fig 8
10 - Tapered roller bearing outer race
^ Pulling out, Refer to Fig. 12
^ Pressing in, Refer to Fig. 13
^ Pressing in, Refer to Fig. 14
^ Transmissions from 06 04 0 secured with locking plate and bolt.
^ Bolt 12 Nm
^ Always replace
11 - Clutch housing
^ Transmissions from 06 04 0, with additional threaded hole and recess for locking plate to secure tapered roller bearing outer race for input shaft -item 10





Fig. 1 Pressing tapered roller bearing outer race out of transmission housing
A - Counter support, e. g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7





Fig. 2 Pressing tapered roller bearing outer race into transmission housing
^ Support transmission housing with press piece 3062 directly below bearing support.





Fig. 3 Pulling off tapered roller bearing inner race
A - Vice clamps/vice
^ First remove securing clip.
^ Before setting up pulling device, set extension 3161 and thrust plate 40-105 on input shaft.





Fig. 4 Pressing off 5th gear
A - Separating device 22 to 115 mm, e.g. Kukko 17/2





Fig. 5 Pressing off 3rd, 4th and 6th gear





Fig. 6 Pressing off tapered roller bearing inner race
A - Separating device 22 to 115 mm, e g. Kukko 17/2





Fig. 7 Pressing on 3rd, 4th and 6th gear
^ Heat gear wheel to about 100°C
^ Press on gear wheel quickly so that heat is not immediately transferred to input shaft.





Fig. 8 Pressing on tapered roller bearing inner race





Fig. 9 Pressing on 5th gear





Fig. 10 Pressing on tapered roller bearing inner race
^ Determine circlip and install, Refer to Fig. 11





Fig. 11 Determining thickness of circlip
^ Determine thickest circlip which will just fit and install it.
The following circlips are available:








Fig. 12 Pulling tapered roller bearing outer race out of transmission housing
A - Counter support, e. g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7





Fig. 13 Outer race/tapered roller bearing installation position in clutch housing
^ Transmissions from 06 04 0
^ The recesses for locking plate (Refer to Fig. 14) on outer race/tapered roller bearing -arrow A- and clutch housing -arrow B- must align.





Fig. 14 Pressing in tapered roller bearing outer race
^ Transmissions from 06 04 0
^ After pressing in, check if the locking plate -A- can be inserted in the recess.
^ Before installing and securing the locking plate, the drive shaft must be inserted.